Edge & Flow Podcast: Recent Episodes
TJ Schwarz & Lucas Burnley
Edge & Flow Podcast is a joint effort between knife makers TJ Schwarz and Lucas Burnley, your hosts. Free flowing, unscripted conversations unfold as we endeavor to explore the knife industry, craftsmanship, business, creativity, and beyond.
Lucas and TJ reflected on their first year in their new shop, discussing their transition from a garage setup to a mature production company and highlighting their progress with various manufacturing processes. They explored the integration of forging and CNC machining techniques in knife making, while emphasizing the importance of learning from experienced manufacturers and accessing available resources for process improvement. The conversation concluded with discussions about industry trends, branding strategies, and the personal fulfillment found in creating unique knife designs, along with reflections on their business growth and future plans.
In this meeting, TJ and Lucas discussed a recent fire incident at a nearby bar and the importance of having business insurance, which TJ confirmed was in place for his shop. They reviewed their Thanksgiving holiday plans and Black Friday sales strategy, noting the success of their first-year discount promotion. The conversation then shifted to manufacturing topics, including Haas's equipment expansion, tool storage solutions, and various prototyping methods for knife-making, with particular focus on design processes, bevel grinding fixtures, and the importance of documentation and revision control in their work.
Lucas shared his hunting experiences and reflections on gear reliability, while comparing hunting to his work as a knife maker. TJ discussed fixture upgrades for knife models and manufacturing processes, including challenges with materials and vacuum forming techniques. The conversation concluded with discussions about documentation systems, project management tools, and the importance of aligning new product offerings with brand value propositions in the knife industry.
TJ and Lucas discussed TJ's journey in knife manufacturing, including his transition from fixed blades to folders and the challenges of prototype production and scaling operations. They explored strategies for diversifying TJ's business while maintaining his existing product line, with Lucas sharing insights on balancing growth and production efficiency. The conversation concluded with discussions about shop setup, including equipment purchases and layout changes, while touching on industry trends and market conditions in the knife industry.
In this meeting, TJ and Lucas discussed their experiences at the Blade Show West and Lucas's plans to refocus on custom folders, while also addressing machine maintenance issues and tool life challenges. They explored various solutions for Lucas's shop, including air compressor options and the importance of understanding financial statements for business decisions. The conversation concluded with a discussion about the value of networking and seeking advice from experienced individuals to help grow their businesses.
Lucas and TJ discussed the upcoming Blade Show West and its unique characteristics compared to other knife shows, emphasizing its value for newer collectors and employees seeking firsthand customer interaction experience. They explored various business aspects of the knife industry, including pricing strategies, market dynamics, and the challenges of scaling operations, while examining successful companies like Benchmade and Montana Knife. The conversation concluded with discussions about the industry's evolution, focusing on technological advancements, changing manufacturing processes, and the potential for new companies to emerge and succeed in the knife market.
Lucas and TJ discuss a Worksharp sponsored salmon fishing trip and the importance of spending time with colleagues outside of a work environment.
Ernest Emerson shares his journey from martial arts enthusiast to renowned knife maker, detailing how his upbringing in Wisconsin, passion for functionality, and chance encounters with Navy SEALs shaped his career path from custom knife making to founding his own successful company. He discusses his business philosophy of treating employees like family, his approach to collaborations with major knife manufacturers, and his commitment to maintaining craftsmanship despite technological advances in the industry. Ernest also reveals his diversification strategy beyond knives, including apparel and whiskey businesses, while offering advice to aspiring entrepreneurs about full commitment, honest self-assessment, and maintaining ownership rather than seeking early investors.
The episode began with Lucas sharing his experience with burnout and his efforts to develop better self-care routines and work patterns, including using tools like ChatGPT to map out his workflow. Burnley and TJ discussed the challenges of balancing maintenance-focused work with creative projects in their businesses, with TJ sharing his realization about spending too much time on maintenance issues. The conversation concluded with a discussion about social media platforms, particularly Instagram and TikTok, including their evolving roles, decreasing engagement, and the impact of AI-generated content, as well as plans for shop organization and machine usage.
Lucas and TJ return from a podcast hiatus. This episode is a recap of Pacific Northwest Custom Invitational as well as shop happenings over the last few months.
Neither Luc nor TJ are attending Blade Show 2025. This was a big decision and made for good discussion.
Luc returns from Blade Show Texas and has a new machine on the way. TJ has a big bevel grinding breakthrough.
Lucas announces his investment property purchase and plans to replace his Haas. The conversation migrates to philosophy and the things that motivate different creative minds.
Luc and TJ discuss business trajectory after Luc toured the Good Art facility over the holidays.
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It was a huge year of struggle, learning, and growth for Luc, TJ, and friends of the podcast.
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The X9 is Reeve grinding. Crucible (CPM) has announced the potential for a closure.
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Both TJ and Luc have a machine down. Discussion about healthy growth later ensues.
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Luc recaps the dinner and trunk show he put on in San Jose. The Syil X9 has almost landed at the Schwarz shop.
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Kydex sheath design and process development never ends.
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Kihoku production continues, a new machine is coming, and Blade Show West was a blast!
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TJ returns from The Maker's Syndicate. Lucas continues his effort to strengthen his brand's social media presence.
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Lucas and TJ get some R&R. Issues with a mismatch between the Tormach and the Syil appear.
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In addition to general shop updates, Luc and TJ discuss peripheral products and brand image awareness.
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Luc returns from PNWCI. Discussion ensues about building a business that can be steered.
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After Blade Show and a long month of personal commitments... we're back.
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Blade Show prep is in full swing. Lucas is excited about completing his first fully CNC machined fixed blade. Machine purchase discussion ensues.
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Lucas kills a turkey and gains insight on hunting knife design. The LT5 is in production!
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Jens Anso is a world class knife maker and designer as well as a long time friend of the pod. He was an obvious choice for our first ever guest.
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Developing products that you like vs. what you think will sell.
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A more technical episode about various finishes on Magnacut. Updates on the LT5 and various production battles.
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The 2x72 belt grinder can be the ultimate neck kinker. Also, Luc brings up time management challenges.
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Lucas talks about a great experience at Blade Show Texas. Schwarz Knives has officially moved.
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The Schwarz Knives shop is closer to completion. Constant improvement mentality, can it be toxic?
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What sells and why? SHOT Show is going on and the Schwarz shop continues the moving process.
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This week was chaotic. Also, the lease is signed. Schwarz Knives is moving.
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In the last episode we spent some time reminiscing on 2023. Now it's time to look forward.
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2023 was a whirlwind year. Luc and TJ recap their successes and struggles of the last 12 months.
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Luc gets surgery, shop updates, Instagram scare and laser vs waterjet.
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Cad courses are coming along and knives are hard to name.
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Luc and TJ answer questions from the Patreon group. Including one very big question.
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Jens Anso puts in some travel miles, Luc works to migrate his CAD workflow to Fusion 360, and TJ recaps Blade Show West.
Luc and TJ talk about the benefits and drawbacks of slow business growth as well as various adjustments to their business models.
Luc returns from a successful outing at the USN Gathering in Las Vegas, TJ and Luc celebrate Terns arriving in customer hands for the first time.
We have a lot of random things to talk about and we briefly have two guests on the podcast.
Luc and TJ continue progress on the collaboration project. Conversations about business growth ensue.
We are happy to announce that the podcast has officially survived one year! Thank you all for supporting us over the last 12 months.
New product development decisions. Do fixed blade knives need weight relief? Should the scales be removable?
Employees, Fusion is down, Nova-1, Down Shifts, pre-orders, international shipping, and new cats!
Lucas interviews TJ on his CAD strategies and philosophies. We finally renamed Red X day.
We're turning the spotlight on Lucas today for a deep dive on the magical world of brand building.
What does the inside of a design licensing deal look like from beginning to end? You're about to find out.
We went into this episode with no topic in mind, but the conversation seemed to revolve around various sticking points involved with growth.
Another more random episode. Blade Show West is coming up, the Syil is cranking out Overlands and Luc is continuing his process of perfecting his weekly schedule.
The schedule of the maker and the manager and how they are different. From here on out episodes will begin to include more general shop updates.
In a one man shop we've found difficulty switching back and forth from designing new product to making existing products.
Join our general conversation on the concept of multitasking in shop and business environments.
Is promoting ourselves important? How do we put it on balance with being productive in other ways.
Trips, new machines, whole shop air systems. We have a lot going on and wanted to recap our last few weeks.
Young kids and running a business from home. Here are our thoughts on the never ending balancing act.
Computer Aided Design, otherwise known as CAD, has swept the knife industry in the last few decades. What does this mean for the maker?
Blade Show 2022 was an amazing experience. Join us in an overview of this year's show as well as Blade Show in general.
In this episode we explore our reasons for making a full time career in the knife industry.